HTP Hydra Smart RT-199 Manual de usuario

LP-532 REV. 8.13.2014 LP-532 REV. 8.13.2014

Service Manual

HYDRA SMART RESIDENTIAL WATER HEATER

Hydra Smart Residential Water Heater

Service Manual

RT-199 (Residential Water Heater)

• Natural Gas(NG)– Factory Default

• Liquid Propane Gas (LP)– Contact Factory

Model

Hydra Smart Residential Water HeaterService Manual

WARNING

– Donotstoreorusegasolineorother󰘱ammablevaporsandliquidsinthevicinityofthisoranyotherappliance.

– WHAT TO DO IF YOU SMELL GAS

· Donottrytolightanyappliance.

· Donottouchanyelectricalswitch;donotuseanyphoneinyourbuilding.

· Immediatelycallyourgassupplierfromaneighbor’sphone.Followthegassupplier’sinstructions.

· Ifyoucannotreachyourgassupplier,callthe󰘰redepartment.

– Installationandservicemustbeperformedbyaquali󰘰edinstaller,serviceagencyorthegassupplier.

Iftheinformationintheseinstructionsisnotfollowedexactly,a󰘰reorexplosionmayresult,

causingpropertydamage,personalinjury,ordeath.

120 Braley Road, East Freetown, MA 02717 •1-800-323-9651 •www.htproducts.com

SCAQMD Rule 1146.2

Advanced Heating

& Hot Water Systems

LP-532 REV. 8.13.2014 LP-532 REV. 8.13.2014

Chapter 1 Product Characteristics Speci󰘰cations 6

Dimensions 7

Components description 8

Flow chart 9

Time chart 10

Operation󰘱owchart 11

Wiring diagram 13

Chapter 2 Components description Maincontrolboard 17

Temperature sensors 18

Burner overheat switch 19

Freeze Protection Heater 20

Gas leak detector sensor 21

Jumper wire connection 22

Air Pressure switch 23

Mixing valve (DHM) 24

Flow control valve (IWM) 25

Inletwater󰘰lter 26

Ignition Transformer 27

Flame Detection Sensor 28

Air Gas mixer (AGM) 29

Gas valve 30

BLDC motor 31

MetalFiberPremixBurner 32

Heat exchanger 33

Condensate trap 34

Chapter 3 How to use control panel Function explanation 35

Control panel 36

ControllerLCDSpeci󰘰cation 36

Control Panel Mode 36

Domestic hot water temperature control 38

Domestic hot water high temperature control 38

Water flow rate 39

Fan speed 39

Lock mode 40

Operating temperature (Heat Exchanger) 40

DHW Outlet Water Temperature 41

Exhaust Gas Temperature. 41

DHW Inlet Water Temperature. 42

Supply Power Time (X 10 hours) 42

View Burner Operating Time (unit: 1 Hour) 43

View Burner Operating Time (unit: X1000 Hr) 43

View Ignition Cycles (cycles X 10 times) 44

View Ignition Cycles (cycles X 10,000 times) 44

Fault Code History 45

Clear Error Code History 45

System Reset 46

Change DHW flow rate measurement unit 46

Fan, Max RPM Adjustment 47

Fan, Min RPM Adjustment 47

Cascade Mode Setting 48

Common Vent Mode Setting 48

Cascade Master/Slave Setting 49

Number of Cascade water heater 49

Reset Burner Operating Time 50

Reset Ignition Cycles 50

AGM value correction 51

Flame Detection 52

Gas Detection 52

Sensing Air Signal 53

‘I/T’, ‘DHW’, ‘OP’ sensors 53

LP-532 REV. 8.13.2014 LP-532 REV. 8.13.2014

Chapter 4 Troubleshooting Error code. 54

Er 10 56

Er 11 57

Er 16 58

Er 20 59

Er 29 60

Er 31 61

Er 32 62

Er 33 63

Er 35 64

Er 38 65

Er 39 66

Er 40 67

Er 41 68

Er 42 69

Er 43 70

Er 65 71

Er 66 72

Er 67 73

Er 72 74

Er 73 75

Er 94 76

Chapter 5 Replacement instructions Main Controller 77

Ignition Transformer 78

Flame Detection Sensor 79

Gas leak detector 79

Air Pressure Switch 80

Gas valve 81

Condensate trap 82

Flow control sensor 83

Cold water inlet filter assembly 84

Cold water inlet filter 85

Mixing valve 85

Air gas mixer(AGM) 86

BLDC Fan assembly 87

Chapter 6 Maintenance Cleaning Air Intake Filter 88

Cleaning Cold Water Inlet Water 88

Flushing Water Heater Pipe 89

Chapter 7 Components diagram Cabinet Parts 90

Heat exchanger parts 91

Memo 92

LP-532 REV. 8.13.2014 LP-532 REV. 8.13.2014

Model Name RT-199

Gas Input Rate MAX 199,000 Btu/h

MIN 19,900 Btu/h

Hot Water Capacity

35°F Rise 11.0Gal

45°F Rise 8.5Gal

77°F Rise 5.0Gal

Installation Indoor, Wall Hung, Fully Condensing

Flue System SealedCombustionDirectVent

VentRun 2”(15ft),3″(100ft)Schedule40PVC,CPVC,PP

Ori󰘰ceSize NG(Ori󰘰ce/Needle) 9.5mm(0.374˝)/9.5mm(0.374˝)

LP(Ori󰘰ce/Needle) Consult the factory

Gas Supply Pressure NG 3.5˝WCto14˝WC

LP 3.5˝WCto14˝WC

Manifold Pressure Min(3″) NG:-0.01”WC,LP:-0.11”WC

Max(3″) NG:-0.03”WC,LP:-0.09”WC

Power Supply

Main Supply 120V60Hz

Maximum

Power Consumption 135W

Ignition System Direct Electronic Ignition / Automatic Flame Sensing

Burner System SingleOri󰘰cePremixedFuelModulationMetalFiber

Infrared

GasValveSystem Air ratio valve

Minimum Flow Rate 0.5GPM

Internal Pipe Material Stainless Steel

Dimensions W17.3″–H27.6″–D14.8″

Weight 88lbs

SubHeatExchangerWaterCapacity(DHW) Under 2 Gallon

Control Panel / Main Controller P-920C / GTH-9500C

Water Pressure Min 15 - Max 150 PSI

Connection Sizes

Cold Water Inlet /

Hot Water Outlet 3/4″NPT

Gas Inlet 3/4″NPT

Materials

Casing ColdRolledCarbonSteel

Heat Exchanger Primary Heat Exchanger : Stainless Steel

Secondary Heat Exchanger : Stainless Steel

Safety Devices

FlameRod,BurnerOverheatCutO󰘯Device(302F/150C),

Gas Leak Detector, Exhaust High Limit Switch

(149F/65C), Freeze Protection Ceramic Heater (turns on

at41F/5C,turnso󰘯at59F/15C),Watertemperaturelimit

switch(199F/93C).

Chapter 1 Product Characteristics

LP-532 REV. 8.13.2014 LP-532 REV. 8.13.2014

Description Diameter

A Exhaust Outlet Pipe collar 3˝

B Air intake collar 3˝

C Gas Inlet Adapter 3/4˝

D DHW Outlet Adapter 3/4˝

E DHW Inlet Adapter 3/4˝

F Condensate drain 1/2˝

GDHWInlet󰘰lter N/A

NO Name of Component

ExhaustVentAdapter

Air Intake Adapter

AGM(Air Gas Mixer)

Ignition Transformer

Igniter

Flame Detection Sensor

PrimaryHeatingExchangerAssembly

Hot Water Outlet Pipe

MixingValve

Air Pressure Switch

N/A

Manual Power Switch

WaterAdjustmentValve

Main Controller

SecondaryHeatExchangerAssembly

Gas Inlet Pipe 1

Flame sight glass

Burner Case

NO Name of Component

Exhaust Duct

GasValve

Gas Inlet Pipe 2

BLDC Fan

Air Intake Pipe Adapter

Gas Inlet Adapter

Freeze Protector

DHW Outlet Adapter

Condensate Trap

Cold Water Inlet Adapter

Cold Water Inlet Filter

Control Panel

OP NTC

H/L Overheat Switch

Ceramic Heater

DHW NTC

Condensate Trap Hose

Burner Overheat Switch

Chapter 1 Product Characteristics Chapter 1 Product Characteristics

910

LP-532 REV. 8.13.2014 LP-532 REV. 8.13.2014

FAN

3s 1.5s2s

180s

3s 1.5s2s 10s 1.5s2s

■If normal ignition

Time chartFlow chart

■If Flame Extinguishes

■ Ifabnormalignition(Alarmafterthe10trial)

IGNITION

GASVALVE

FLAME DETECTION

Chapter 1 Product Characteristics Chapter 1 Product Characteristics

11 12

LP-532 REV. 8.13.2014 LP-532 REV. 8.13.2014

Chapter 1 Product Characteristics Chapter 1 Product Characteristics

Check setting

values (Setting

Temp, Errors)

Initializing equipment

(Timer, Stepping Motor, Gas Valve and

Others)

Clear Watchdog

Check

communication

Check A/DC

Check Error

Check Water Flow

(ignore below 0.39

GPM)

Igniter, Gas

Valve "OFF"

RPM for Pre-purge,

Time Setting

Set RPM for

Pre-purge

Setting for Fan

stop

MCU Testing

Igniter "ON"

Gas Valve "ON"

Igninter "OFF"

Check Fan RPM

Water Flow >= 0.39 GPM, and

Doesn't have Error (Front Panel

"ON")

Step for

Pre-purge

Water Flow >=

0.53 GPM

Step for

Post-purge

Post-purge time

setting RPM

Finish for

Pre-purge

Check condition

for RPM, Flame

Ignition

Igniter "ON"

Time >=

1.5 sec

Gas Valve "On"

Time >= 2sec

Detecting RPM,

Flame (Normal)

MCU testing

cycle >= 30min

Decide controlling calue for Fan,

Mixing valve, AGM, IWM

Gas Valve

"OFF"

Start

MCU Testing

Check Error

Flame Extinction >=

8 times

Ignition Failure >=

10 times

Water Temperature

>= 199 ℉

Opened High Limit

Opened value for

APS

Inlet Temperature

sensor Open or

Short

Exhaust

Temperature sensor

Open or Short

Inlet Temperature

sensor Open or

Short

Exhaust

Temperature sensor

Open or Short

Abnormal MCU

Detecting

False-flame

Detecting Gas

leakage

Jumped Wire

Connection

Tilt Switch Open

and/or Short

Burner High Limit

Switch Switch

Cut-off

Abnormal RPM

sensor

Zero reference error

of supply water

valve

Zero reference error

of mixing valve

Failed self test of

MCU's internal

device

MCU Error

Flame is detected

before ignition

Abnormal DIP

switch setting

Communication

failure

Exhaust

Temperature >=

149℉

ERROR 10

ERROR 11

ERROR 16

ERROR 20

ERROR 29

ERROR 31

ERROR 32

ERROR 33

ERROR 35

ERROR 38

ERROR 39

ERROR 40

ERROR 41

ERROR 42

ERROR 43

ERROR 61

ERROR 65

ERROR 66

ERROR 67

ERROR 70

ERROR 72

ERROR 73

ERROR 76

ERROR 94

C heck s etting

values (S etting

Temp, E rrors )

Initializing equipment

(Timer, S tepping Motor, G as V alve and

Others )

C lear W atchdog

C heck

communication

C heck A/DC

C heck E rror

C heck W ater F low

(ignore below 0.39

G P M)

Igniter, Gas

V alve "OF F "

R P M for P re-purge,

Time S etting

S et R P M for

P re-purge

S etting for F an

stop

MC U T es ting

Igniter "ON"

G a s V a lve "O N"

Igninter "OF F "

C heck F an R P M

W ater F low >= 0.39 G P M, and

Doesn't have E rror (F ront P anel

"ON")

S tep for

P re-purge

Water F low >=

0.53 G P M

S tep for

P os t-purge

P os t-purge time

s etting R P M

F inish for

P re-purge

C heck condition

for R P M, F lame

Ignition

Igniter "ON"

T ime >=

1.5 sec

G a s V a lve "O n"

T ime >= 2s ec

Detecting R P M,

F lame (Normal)

MC U tes ting

cycle >= 30min

Decide controlling calue for Fan,

Mixing valve, AG M, IW M

G a s V alve

"O F F "

S tart

MC U T es ting

C heck E rror

F lame E xtinction >=

8 times

Ignition F ailure >=

10 times

W ater T emperature

>= 199 ¢ µ

Opened High Limit

Opened value for

AP S

Inlet T emperature

sens or O pen or

S hort

E xhaus t

T emperature s ensor

Open or S hort

Inlet T emperature

sens or O pen or

S hort

E xhaus t

T emperature s ensor

Open or S hort

Abnormal MC U

Detecting

F als e-ame

Detecting Gas

leakage

Over range of

s etting R P M

Jumped Wire Disconnected

B urner High Limit

S witch S witch

Cut-o

Abnormal R P M

sens or

Zero reference error

of s upply water

valve

Zero reference error

of mixing valve

F ailed self tes t of

MC U's internal

device

MC U E rror

F lame is detected

before ignition

Abnormal DIP

switch setting

C ommunication

failure

E xhaus t

T emperature >=

149¢ µ

E R R OR 10

E R R OR 11

E R R OR 16

E R R OR 20

E R R OR 29

E R R OR 31

E R R OR 32

E R R OR 33

E R R OR 35

E R R OR 38

E R R OR 39

E R R OR 40

E R R OR 41

E R R OR 42

E R R OR 43

E R R OR 61

E R R OR 65

E R R OR 66

E R R OR 67

E R R OR 70

E R R OR 72

E R R OR 73

E R R OR 76

E R R OR 94

Operation Flow Chart Operation Flow Chart

C heck s etting

values (S etting

Temp, E rrors )

Initializing equipment

(Timer, S tepping Motor, G as V alve and

Others )

C lear W atchdog

C heck

communication

C heck A/DC

C heck E rror

C heck W ater F low

(ignore below 0.39

G P M)

Igniter, Gas

V alve "OF F "

R P M for P re-purge,

Time S etting

S et R P M for

P re-purge

S etting for F an

stop

MC U T es ting

Igniter "ON"

G a s V a lve "O N"

Igninter "OF F "

C heck F an R P M

W ater F low >= 0.39 G P M, and

Doesn't have E rror (F ront P anel

"ON")

S tep for

P re-purge

Water F low >=

0.53 G P M

S tep for

P os t-purge

P os t-purge time

setting R P M

F inish for

P re-purge

C heck condition

for R P M, F lame

Ignition

Igniter "ON"

T ime >=

1.5 sec

G a s V a lve "O n"

T ime >= 2s ec

Detecting R P M,

F lame (Normal)

MC U tes ting

cycle >= 30min

Decide controlling calue for Fan,

Mixing valve, AG M, IW M

G a s V alve

"O F F "

S tart

MC U T es ting

C heck E rror

F lame E xtinction >=

8 times

Ignition F ailure >=

10 times

W ater T emperature

>= 199 ¢ µ

Opened High Limit

Opened value for

AP S

Inlet T emperature

sens or O pen or

S hort

E xhaus t

T emperature s ensor

Open or S hort

Inlet T emperature

sens or O pen or

S hort

E xhaus t

T emperature s ensor

Open or S hort

Abnormal MC U

Detecting

F als e-ame

Detecting Gas

leakage

Over range of

s etting R P M

Jumped Wire Disconnected

B urner High Limit

S witch S witch

Cut-o

Abnormal R P M

sens or

Zero reference error

of s upply water

valve

Zero reference error

of mixing valve

F ailed self tes t of

MC U's internal

device

MC U E rror

F lame is detected

before ignition

Abnormal DIP

switch setting

C ommunication

failure

E xhaus t

T emperature >=

149¢ µ

E R R OR 10

E R R OR 11

E R R OR 16

E R R OR 20

E R R OR 29

E R R OR 31

E R R OR 32

E R R OR 33

E R R OR 35

E R R OR 38

E R R OR 39

E R R OR 40

E R R OR 41

E R R OR 42

E R R OR 43

E R R OR 61

E R R OR 65

E R R OR 66

E R R OR 67

E R R OR 70

E R R OR 72

E R R OR 73

E R R OR 76

E R R OR 94

13 14

LP-532 REV. 8.13.2014 LP-532 REV. 8.13.2014

CN11

CN9

CN10 CN12

CN8

CN6

CN1

CN3

CN14 CN4

CN5

CN7

Wiring diagram

Chapter 1 Product Characteristics Chapter 1 Product Characteristics

Jumper Wire

15 16

LP-532 REV. 8.13.2014 LP-532 REV. 8.13.2014

Connector

Descriptions HT

SELV

no. of location and

type Pin nr. Board Silk

CN9

65001WS-12

1 - Unused -

2 L Power Supply Line HT (120VAC)

3 CP1 Unused HT (120VAC)

4 IT Igniter HT (120VAC)

5 L(HT) Heater HT (120VAC)

6 GV Gas Valve HT (120VAC)

7 EARTH GROUND HT (120VAC)

8 N Power Supply Neutral HT (120VAC)

9-12 N AC Power COM Line HT (120VAC)

CN1

SMW250-03

RS-485

RS485 + SELV (5VDC)

2 GND SELV (5VDC)

3 RS485 - SELV (5VDC)

CN4

LWD1140-06

FAN

Unused -

2 GND SELV (30VDC)

3 VDD SELV (14VDC)

4 Fan power(start coil) SELV (30VDC)

5 Fan power(end coil) SELV (30VDC)

6 Fan speed feedback signal SELV (14VDC)

CN8

SMW250-04

MCU ISP

GND SELV (5VDC)

2 ISP /Reset port SELV (5VDC)

3 ISP TOOL0 Data port SELV (5VDC)

4 VCC SELV (5VDC)

CN11

LWD1140-16

1HWL Unused -

2LWL Unused -

3HD Unused -

4TH Connect to the Display Con-

trol(Thermostat) SELV (14VDC)

5APS Air Pressure Switch SELV (14VDC)

6EL Jumper Wire SELV (14VDC)

7BL Burner Limit SELV (14VDC)

8HL High Limit SELV (14VDC)

CN5

SMW250-10

1RPM FAN RPM Check SELV(5VDC)

2GND SELV(5VDC)

Connector

Description HT

SELV

no.oflocationand

type

nr.

Board

Silk

CN7

LWD1140-14

1F.S Flame Detect Sensor SELV(5VDC)

2OP.S Operation water temperature sensor SELV(5VDC)

3DH.S DHW temperature sensor SELV(5VDC)

4I.S Inlet water temperature sensor SELV(5VDC)

5BG.S Exhaust temperature sensor SELV(5VDC)

6ST.S Unused -

7SP.S Unused -

CN12

SMW250-07

AGM

AGM Stepper motor coil /Y phase SELV(24VDC)

2AGM Stepper motor coil Y phase SELV(24VDC)

3AGM Stepper motor coil /X phase SELV(24VDC)

4AGM Stepper motor coil X phase SELV(24VDC)

5GND SELV(24VDC)

6AGM Stepper motor position SELV(14VDC)

7VDD SELV(24VDC)

CN10

SMW250-08

DHM

DHM Stepper motor coil /Y phase SELV(14VDC)

2DHM Stepper motor coil Y phase SELV(14VDC)

3DHM Stepper motor coil /X phase SELV(14VDC)

4DHM Stepper motor coil X phase SELV(14VDC)

5GND SELV(14VDC)

6DHM Stepper motor position SELV(14VDC)

7Unused SELV(14VDC)

8VDD SELV(14VDC)

CN14

SMW250-09

IWM

GND SELV(14VDC)

2IWM Stepper motor position SELV(14VDC)

3VDD SELV(14VDC)

4IWM Stepper motor coil X phase SELV(14VDC)

5IWM Stepper motor coil Y phase SELV(14VDC)

6VDD SELV(14VDC)

7IWM Stepper motor coil /X phase SELV(14VDC)

8IWM power IWM Stepper motor coil /Y phase SELV(14VDC)

9Unused -

CN3

SMW250-06

WPS

Unused SELV(5VDC)

2Unused SELV(5VDC)

3Unused SELV(5VDC)

FLUX1

VCC SELV(5VDC)

5Water Flow Sensor SELV(5VDC)

6GND SELV(5VDC)

Chapter 1 Product Characteristics Chapter 1 Product Characteristics

17 18

LP-532 REV. 8.13.2014 LP-532 REV. 8.13.2014

Description/Part # Main Control Board / 7850P-058 Check Point

(Main PCB) N/A

Function This part controls all components contained in the water heater

Failure Event Abnormalmaincontrolleroperation.

E󰘯ects Whenthemaincontroller hasabnormalcondition,componentsmaynotoperate

properly.

Error Code Er 38

Diagonostic Check each connection and/or wires damage on the PCB

Color/WireNumber N/A

Exhaust temperature Sensor

Water inlet temperature sensor

Heat Exchanger temperature

Water outlet temperature sensor

NO Item Standard

Temperature –

Resistance Type

Idling Condition

Temperature(℃) Resistance(kΩ)

0 ± 0.1 ℃-10.99

25 ± 0.1 ℃-3.906

85 ± 0.1 ℃0.552 ± 3%

Blank is for reference measurement

2B Fixed Number

(25/85) 3482.4K ± 2%

3Fixed Number of

Heat dissipation 2.5mW/℃(Min.) (While not boiling)

4Fixed Number of

Heating

8(15)Sec (Max)(63.2% reaching time

while boiling)

5Range of Workable

Temperature -4 ~ 230 F

①②③④⑤⑥⑦

⑧⑨⑩⑪⑫⑬⑭

Chapter 2 Components description Chapter 2 Components description

CN7

Description/Part #

HX Temperature Sensor / 7850P-081

ExhaustTemp.Sensor/7850P070

Water Outlet Sensor / 7850P-019

Water Inlet Sensor / 7850P-015

Check Point

(Main PCB) CN7

Function The controller compares each sensor with setting temperature then goes to safety

shutdownwhenmeasuredtemperatureisoversettingtemperature.

Failure Event Sensormalfunctionoroverheatingconditionisdetected.

E󰘯ects Impropertemperaturemeasurement.

Error Code Er 16, Er 31, Er 33, Er 35

Diagonostic ①Checktemperaturesensorswiringconnection.

②measuresensorresistanceusingamultimeter.

Color/WireNumber

①Exhausttemperaturesensor(white/blue):Connector⑤,⑫

②WaterInlettemperature(blue/blue):Connector④,⑪

③HeatExchangerTemperatureSensor(white/black):Connector②,⑨

④WaterOutletTemperature(yellow/yellow):Connector③,⑩

Otros manuales para Hydra Smart RT-199

Tabla de contenidos

Otros manuales de Calentador de agua de HTP

HTP

HTP SSC-35 Manual de usuario

HTP

HTP Phoenix Series Instrucciones de instalación y funcionamiento

HTP

HTP SuperStor Contender SSC-50SB Manual de usuario

HTP

HTP SuperStor Ultra SSU-20 Manual de usuario

HTP

HTP EVR 040 Manual de usuario

HTP

HTP Phoenix PH76 Manual de usuario

HTP

HTP Superstor Ultra SSU-20N Manual de usuario

HTP

HTP EVERLAST Manual de usuario

HTP

HTP Hydra Smart Series Manual de usuario

HTP

HTP RGH-150 Guía

HTP

HTP SuperStor Pro Solar SE Series Manual de instalación

HTP

HTP SB Series Manual de instalación

HTP

HTP Elite XL ELX-400 Manual de instalación

HTP

HTP RGH-199 Manual de instalación

HTP

HTP Everlast EV-6 Manual de instalación

HTP

HTP RGH-150 Manual de usuario

HTP

HTP PH130-80S Manual del propietario

HTP

HTP Hydra Smart RT-199 Guía

HTP

HTP HPW-50-6 Manual de instalación

HTP

HTP Superstor Ultra SSU-30CB Manual de usuario

HTP

HTP Everlast EVC080 Manual de usuario

HTP

HTP EVG080C2X045H Manual de usuario

HTP

HTP Crossover RGH20-75F Guía

HTP

HTP DB Series Manual de usuario

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Toyotomi Oil Miser OM-180 Manual de usuario

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Bradford White EF Series Manual de usuario

Eccotemp

Eccotemp 40-H Manual de usuario

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Dimplex ECSd125-580 Guía

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Toyotomi Oil Miser OM-148 (Type D) Guía de solución de problemas

Noritz

Noritz N-132M Manual de instrucciones

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TESY GCV7/4S 10047 Hoja de especificaciones

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A.O. Smith Gphe 50 Manual de usuario

Koryo

Koryo KWHZF15Y Manual de usuario

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Pentair PSC-14-4-02 Manual de usuario

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Thermor AEROMAX SPLIT 2 Manual de usuario

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American Hometec AHQ-B03X Manual de usuario